NHTSA Office of Defects Investigation

Engineering Analysis EA03-008: FUEL TANK LEAKS

Closed

NHTSA's Office of Defects Investigation opened Engineering Analysis EA03-008 on June 11, 2003 and closed it on July 28, 2004. NHTSA's investigations file lists the 1993–1996 Volvo 850 for it and links recall 04V-368 to it.

Updated daily from NHTSA's investigations file

Key facts

NHTSA number: EA03-008 (also written EA03008)
Investigation type: Engineering Analysis A more detailed stage of a defect investigation, opened when NHTSA's Office of Defects Investigation decides an issue merits further review, often after a Preliminary Evaluation or a Recall Query; it can include vehicle testing, surveys and further information requests.
Status: Closed July 28, 2004
Opened: June 11, 2003
Closed: July 28, 2004
Vehicle or equipment manufacturer: Volvo Car USA, LLC
Component: Fuel System, Gasoline — Storage
Recall linked by NHTSA: 04V-368: VOLVO/FUEL TANK, reported July 30, 2004
Vehicles and equipment: 1993–1996 Volvo 850

NHTSA's summary

As NHTSA's Office of Defects Investigation wrote it for Engineering Analysis EA03-008.

try.vin does not copy NHTSA's investigation documents; NHTSA's investigation record lists the ones NHTSA has published.

THIS ENGINEERING ANALYSIS WAS OPENED ON JUNE 11, 2003, BASED ON 54 REPORTS OF FUEL TANK LEAKS.THE SUBJECT VEHICLES WERE 1993 THROUGH 1996 MODEL YEAR (MY) 850 VEHICLES. MODEL 850 WAS ALSO PRODUCED IN MY 1997 AND WAS INCLUDED IN THIS INVESTIGATION. ANALYSIS OF THE DATA REVEALS TWO DISTINCT ISSUES. FIRST, THE 1994 THROUGH 1997 MY VEHICLES STAND OUT BY ACCOUNTING FOR 95 PERCENT OF THE REPORTED LEAKS.THESE VEHICLES SHARE THE SAME FUEL TANK DESIGN (PN 9142618). THE 1993 MY VEHICLE USES A DIFFERENT FUEL TANK DESIGN (PN 9141101).

SECONDLY, THE FAILURES OCCURRED PREDOMINANTLY IN HOT CLIMATES, E.G., CALIFORNIA, ARIZONA, TEXAS, FLORIDA, GEORGIA, LOUISIANA, ETC.TESTING OF FUEL TANKS FROM CONSUMER VEHICLES AT THE VEHICLE RESEARCH AND TEST CENTER CONFIRMED LEAKS THROUGH CRACKS IN THE FUEL TANK WALL AT A HEAT SHIELD MOUNTING ATTACHMENT IN THE 1994 THROUGH 1997 MY FUEL TANKS (PN9142618). DETAILS OF THE TESTS ARE AVAILABLE IN TEST REPORT VRTC-DCD3060.

VOLVO WILL CONDUCT A SAFETY RECALL ON ALL MY 1994 THROUGH 1997 VEHICLES ORIGINALLY SOLD OR REGISTERED IN THE FOLLOWING 17 HOT STATES: CA, AZ, NM, TX, LA, MS, AL, GA, SC, FL, NC, TN, AR, OK, UT, NV, AND HI.ALL 1994 THROUGH 1997 MY VEHICLES IN ALL OTHER STATES WILL BE REMEDIED UNDER A SERVICE CAMPAIGN.THE REMEDY FOR BOTH THE RECALL AND SERVICE CAMPAIGN IS TO INSTALL A NEW BUSHING AT EACH HEAT SHIELD ATTACHMENT POINT (3 PER TANK).

ALSO, ALL TANKS (VEHICLES IN ALL STATES) WILL BE INSPECTED FOR FUEL SEEPAGE AT THE HEAT SHIELD ATTACHMENT POINTS AND VOLVO WILL REPLACE ANY TANK SHOWING SIGNS OF FUEL SEEPAGE.THE NEW BUSHINGS WILL PREVENT HEAT SHIELD STRESSES FROM BEING TRANSFERRED TO THE THREE HEAT SHIELD MOUNTING ATTACHMENTS ON THE FUEL TANK.THE SAFETY RECALL IS FILED UNDER NHTSA SAFETY RECALL NUMBER 04V368.

THIS INVESTIGATION IS CLOSED.

Vehicles and equipment listed for this investigation

NHTSA's investigations file lists these vehicles and equipment for Engineering Analysis EA03-008. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. Model years with a try.vin recall page link to that page's NHTSA investigations section.

Volvo

Volvo 850
- 1993, 1994, 1995, 1996

All Volvo recalls

What an NHTSA investigation is

NHTSA's Office of Defects Investigation (ODI) looks into possible safety defects in vehicles and equipment, often after owner complaints. An investigation usually starts as a Preliminary Evaluation, or as a Recall Query when it concerns whether an existing recall covers the right vehicles or fixes the problem, and ODI can upgrade it to a more detailed Engineering Analysis. A Defect Petition asks NHTSA to open an investigation, and Audit and Equipment Queries are administrative investigations into whether companies complied with federal vehicle safety requirements, such as reporting, recall and certification rules.

An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

To see whether a specific vehicle has an open recall, enter its VIN at nhtsa.gov/recalls.

Volvo VIN check: decode a VIN to see its year, make and model.

Sources

NHTSA's investigation record for EA03-008

Investigation details come from NHTSA's investigations file, which try.vin imports once a day. The investigation types are described from the U.S. Department of Transportation Inspector General's May 2023 report on NHTSA's Office of Defects Investigation, NHTSA's petition rules (49 CFR Parts 552 and 557) and NHTSA's Office of Defects Investigation procedures. How try.vin reads NHTSA investigations.